US3585352A - Arc welding process and electrode for stainless steel - Google Patents

Arc welding process and electrode for stainless steel Download PDF

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US3585352A
US3585352A US879045A US3585352DA US3585352A US 3585352 A US3585352 A US 3585352A US 879045 A US879045 A US 879045A US 3585352D A US3585352D A US 3585352DA US 3585352 A US3585352 A US 3585352A
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percent
slag
derivative
filler
electrode
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Albert J Zvanut
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Stoody Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
    • B23K35/368—Selection of non-metallic compositions of core materials either alone or conjoint with selection of soldering or welding materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0261—Rods, electrodes, wires
    • B23K35/0266—Rods, electrodes, wires flux-cored
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/308—Fe as the principal constituent with Cr as next major constituent
    • B23K35/3086—Fe as the principal constituent with Cr as next major constituent containing Ni or Mn
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/40—Making wire or rods for soldering or welding
    • B23K35/406—Filled tubular wire or rods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
    • B23K35/3601—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest with inorganic compounds as principal constituents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
    • B23K35/3601—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest with inorganic compounds as principal constituents
    • B23K35/3603—Halide salts
    • B23K35/3605—Fluorides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
    • B23K35/3601—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest with inorganic compounds as principal constituents
    • B23K35/3608—Titania or titanates

Definitions

  • the field of art to which the invention pertains includes the field o arc welding electrodes.
  • Flux-cored electrodes have been utilized in the arc welding of steel for continuous or automatic feeding of the electrode to workpiece.
  • Generally mild steel or low carbon steel (both more accurately termed plain steel) in tubular form is filled with a mixture of fluxing and slag forming agents an deoxidizers to protect the weld against oxidation.
  • Such "bare" electrodes permit direct electrical contact and, as the electrode is melted by the arc, the mixture of materials constituting the core function much in the same manner as if they were coated on the electrode or separately deposited.
  • protective gases are invariably utilized to obtain a clean weld.
  • Such gases as helium and argon are commonly utilized and bulky and expensive gas metering equipmentis required; yet, arc welding with such electrodes in the absence of a protective gas'cover results in pitted and rough welds, embrittled by entrapped oxides.
  • the present invention is concerned with providing a process for arc welding of stainless steel without the formation of porous steel welds.
  • Various novel means are provided for accomplishing this end, which means relate to the use of arc welding electrodes with limited moisture levels.
  • the invention as defined hereinafter by the claims is not to be limited or construed with respect to any theory of operation as the mechanisms herebefore and hereafter presented are presented only by way of possible explanation of the results and effects which constitute my discoveries.
  • I provide a process comprising providing an arc welding flux-cored electrode which is capable of forming a stainless steel weld of desired composition, electrically energizing the electrode, mechanically feeding the electrode toward the workpiece while maintaining an are between the end of the electrode and workpiece, and providing moisture limiting means whereby the electrode is applied to the workpiece with a moisture content of less than 1.0 percent based on the weight of the filler.
  • the moisture limiting means relates to the composition of the electrode flux and to certain ratios of components of the electrode.
  • a suitable electrode comprises a hollow tube of steel having as filler on the inside thereof I) one or more alloying metals in amount sufficient to form a stainless steel weld of desired composition and (2).
  • slag-forming material including av slag-forming first component and a derivativeof a metal having an oxide form when molten different from the first component and soluble in the slag.
  • the steel tube has a diameter of 0.045 to 0.30 inches, the weight ratio of the filler to the steel tube being 0.2/1 to 1.5/1 and the weight ratio of the slag-forming material to the alloying material being 0.15/1 to 0.65/1.
  • a fluxing agent such as calcium fluoride, or a fusion or decomposition derivative thereof, is included as a component of the filler in at least an amount, corresponding to the level of moisture content of the filler, as will yield a nonporous weld.
  • this moisture content is defined by the line A-B of FIG. 2 in the accompanying drawings. It may be theorized that the calcium fluoride reacts with water vapor which may be present to form compounds which are not harmful to the weld. Similarly, calcium carbonate can effect the formation of nonharmful compounds upon reaction with water vapor at the weld temperature. However, it may also be theorized that calcium fluoride and calcium carbonate increase the basicity of the slag which reduces hydrogen absorption by the weld metal.
  • the components of the slag-forming material of the filler are chosen so that this material, or fusion or decomposition derivative thereof, has a relatively low equilibrium moisture content, defined hereinafter as less than 2 weight percent at F. and v9O percent relative humidity.
  • this material or fusion or decomposition derivative thereof, has a relatively low equilibrium moisture content, defined hereinafter as less than 2 weight percent at F. and v9O percent relative humidity.
  • the aforementioned derivative of metal has a basic or amphoteric oxideform when molten, different from the first slag-forming component, whereby the combination of the molten oxide form of the metal derivative and the molten form of the first component is basic or amphoteric.
  • a second derivative of metal having a basic or amphoteric form which is similar in solubility properties to the first derivative of metal mentioned above.
  • the moisture limiting means is provided in the form of an electrically insulative member' which supports the electrode in sufficient extension from its conductive holder whereby resistance heating of the electrode reduces the level of any moisture in the electrode, at the point of application to the workpiece, to the aforementioned limited moisture content.
  • the moisture limiting means is effected by packaging the electrode prior to use in material having a water-vapor transmission rate sufficiently low to maintain a level of moisture in the electrode, prior to use, to the aforementioned limited moisture content.
  • FIG. 1 is a series of cross-sectional views illustrative of a process of manufacturing welding electrode wire of the present invention
  • FIG. 2 is a chart illustrating the relationship of moisture content and calcium fluoride content to porosity of weld deposit
  • FIG. 3 is a side elevational view partly in cross section and somewhat diagrammatic showing apparatus embodying an aspect of the invention.
  • FIG. 4 is a chart showing the relationship of electrode stickout, moisture content and calcium fluoride content to porosity of weld deposit.
  • FIG. I The manufacture of an arc welding electrode of tubular construction enclosing a core composition of this invention is illustrated in FIG. I.
  • a flat strip of metal or tape is first prepared, comprising a metal which may be cold formed and which is a desirable component of-the finished wire electrode.
  • the strip (FlG.'la) may comprise mild steel tape fifteen thirty-seconds inch wide and 0.0095 inch thick.
  • the initial step in fonning the electrode involves developing the strip, as indicated by the arrows 11, into an elongate trough 12 (FIG. 1b) utilizing any of a variety of known techniques.
  • a quantity of filler 14 of this invention is dispensed into the length of the trough 12 by a continuousfeed process.
  • the trough 12 is compressibly closed as indicated by the arrows 16 (FIGS. 1b and until the original strip comprises a closed cylindrical tube 13 (FIG. 1d).
  • the metalworking formation of the strip into a closed tube 18 with the tiller 14 therein may beperformed in production, for example, as disclosed in US. Pat. Nos. l,629,748 and l,640,859,issued toW. F. Stoody. I
  • the ingredients should be reduced to particles which would pass a mesh screen.
  • the ingredients should be reduced to particles which would pass a mesh screen.
  • the resultant mixture can then be compacted,.'baked and then crushed to 20 mesh for tube loading.
  • electrode wire having a diameter of 0.045 to 0.30 inches may be accomplished economically in a continuous production operation and containing a weight ratio of filler to tube of 0.2/1 to 1.5/1.
  • a weight ratio of filler to tube of 0.2/1 to 1.5/1.
  • the electrode filler 14 should comprise (1) one or.
  • slag-forming material including a slag-forming first component and a derivative of a metal having an oxide form when molten different from the first component and soluble in the slag.
  • plain steel is generically descriptive of a variety of steels ranging from low-carbon or mild-steel (typically 0.005 to 0.15 percent carbon content) to high-carbon steel (up to 1.0 percent carbon content) and any of such steels can be utilized as the steel strip.
  • the compositions of this invention are formulated to obtain a stainless steel weld; accordingly, the alloying metals comprise at least 10 weight percent chromium.
  • Other alloying metals include aluminum, molybdenum, nickel, titanium, tungsten, vanadium, zirconium, manganese, columbium, silicon, ferroalloys such as ferrochromium, ferrosilicon,
  • ferrocolumbium ferromanganese, ferromolybdenum, and the like, or any other alloying element or combination thereof added to impart a desired'alloying effect to the stainless steel.
  • the slag-forming first component such materials are well known to the art, such as titanium dioxide (e.g., in the form of rutile, or other natural form), alumina, silicon dioxide (e.g., in the form of .silica flour, feldspar, wollastonite, and the like), manganese dioxide, mixtures of metal oxides, such as asbestos, and the like. Titanium dioxide is a particularly effective slag former. Other slag-formers are known such as potassium titanate and may be utilized in the broadest sense of this invention wherein steps are taken to provide means for limiting the level of moisture in the electrode.
  • such vmaterial is chosen as has a basic or amphoteric oxide form when molten, which molten oxide form is soluble in the slag obtained during welding.
  • One or more such .derivatives may be utilized. Since the molten oxideforms of these derivatives .aresoluble in the slag, they should be chosen so as to not increase the density of the slag beyond that of the weld metal and also should be such, and be present in such amounts, as to impart to the combination of slag forming metal oxide and other slag-soluble components, at the temperature of weld formation, a freezing temperature no higher than the freezing temperature of the weld.
  • viscosity and surface tension of the slag are also of prime importance, (it is generally desired to have a slag of high viscosity and low surface tension). Accordingly, these factors should be balanced when blending the filler, and a combination of derivatives should be utilized which impart such characteristics or which allow such characteristics to be imparted by the addition of other agents.
  • the derivatives are preferably such as to yield basic or amphoteric oxides when molten, in contrast to the commonly used acidic oxide ingredients of the prior art, and are such that their molten combination with the slag-forming metal oxide and fluxing agent results in a basic or amphoteric slag.
  • acidic acidic
  • basic basic
  • amphoteric are well known to those in the welding art; the classification can be made by noting any tendency on the part of the material to react with a strongly basic material like lime (in which case it would be acidic), or a decidedly acidic material like silica (in which case it would be basic or alkaline), or both in the case of amphoteric oxides.
  • nonmetals form acidic oxides and the metals form basic oxides (but particular members of Group IV and higher of the periodic table will often have base, intermediate and acidic oxides, acidic character generally increasing with the oxygen/metal ratio). It may also be advantageous to utilize a metal that is less noble than iron, i.e., that are more electropositive than iron, to avoid any tendency of the derivative to oxidize iron.
  • materials useful as derivatives can be chosen from such compounds as zinc oxide, barium oxide, calcium oxide, calcium carbonate, magnesium oxide, magnesium carbonate, cobalt (lll) oxide, calcium oxalate, strontium oxide, titanium dioxide, manganese dioxide, potassium oxalate, lithium carbonate, zirconium carbonate, zirconium dioxide, gallium sesquioxide, and the like.
  • slag formers Some of the foregoing derivatives were described above as slag formers. in this regard the derivative chosen should be such as to be different from any slag-former utilized in the composition. Particularly effective results have been achieved with manganese dioxide as the sole derivative or in combination with zirconium dioxide or calcium carbonate.
  • the amount of derivative suitably added is governed by factors already considered above, but generally from about 0.1 to about 3 weight percent, based on the electrode of each such material can be added. I
  • the deoxidizer may also be added as part of the filler a deoxidizer and a fluxing agent.
  • a deoxidizer this is added to dispose of oxygen or oxygen-bearing compounds in the molten weld, or to remain in the metal as a safeguard in the event that oxygen should enter.
  • the deoxidizer is a metal having a greater affinity for oxygen than does i'ron so as to preferentially oxidize to thereby reduce iron oxide to iron. More than one deoxidizing metal may be present.
  • deoxidizers includes also metals otherwise termed killing agents.”
  • metals as chromium, tantalum, niobium, gallium, aluminum, silicon, calcium, lanthanum, manganese, vanadium, zirconium, beryllium, titanium, boron, barium, magnesium, strontium, lithium, actinium, and the like or alloys thereof such as ferrosilicon, ferrochromium, ferromanganese, and the like.
  • the high alloy content of stainless steel wires utilized in this invention can allow one to omit the use of elements, such as silicon, for deoxidation purposes, since the high amount of chromium in stainless steel effects deoxidation.
  • fluxing agent such materials are utilized to dissolve oxides formed during welding and it is in this function that the term flux" is utilized here.
  • flux has been utilized by the prior art to also indicate the function of mixing or comingling with an oxide to form a slag of more favorable melting point and viscosity; however, it is difficult in this respect to make a sharp distinction between shielding slags and fluxes, and for this reason the first-above meaning will be utilized.
  • fluxing agents for example, calcium carbonate, calcium oxide (e.g., a calcined limestone), calcium fluoride, (e.g., as fluorspar) and sodium oxide (e.g., as such, or as derived in situ from sodium carbonate or sodium, silicate), and the like.
  • calcium carbonate e.g., calcium oxide
  • calcium fluoride e.g., as fluorspar
  • sodium oxide e.g., as such, or as derived in situ from sodium carbonate or sodium, silicate
  • the materials are added in the form mentioned, but during processing may well be converted to another form in view of the conditions of processing. Also, it is advantageous to utilize only those components which at leastin their finally processed form absorb or adsorb relatively low levels of moisture.
  • Most of the slagforming components of the tiller are hygroscopic to some extent, but I have found that the level of moisture picked up by some components is quite a bit less than the level picked up by other components and that under certain test criteria, the distinction between suitable and nonsuitable components can be demarcated. Specifically, I have found that when various slag-forming materials are subjected to percent relative humidity at 70 F.
  • each component chosen for the slag-forming material have an equilibrium moisture content under the aforementioned conditions of less than 2.0 weight percent, but satisfactory results are obtained if the resultant fully processed composition has that moisture level.
  • the following example illustrates a method whereby the equilibrium moisture content for a variety of materials can be determined.
  • EXAMPLE 1 Approximately 7 grams of each of the materials listed were transferred as samples into preweighed aluminum dishes. The aluminum dishes were placed in an oven operating at 600 F., (or l800 F., as indicated) to drive off moisture content, and were removed, cooled and weighed at hourly intervals until a constant weight was reached (approximately 5 hours were needed). The aluminum dishes were then placed in a humidity chamber at 70 F. under 90 percent relative humidity and then weighed at 24 hour intervals until a maximum was reached or until 216 hours (which, experience has indicated, will indicate whether a material is suitable under the criteria set forth above). The moisture pickup of the sample was then calculated from the weight gain. The following results were obtained for a variety of materials.
  • Those materials having less than 2 weight percent moisture pickup under the above conditions are thus readily determined and are particularly suitable as filler components.
  • other suitable materials include potassium oxide, calcium oxide, sodium oxide and sodium silicofluoride.
  • Those components found to pick up more than about 2 percent moisture should only be used if they are converted during processing of the electrode filler to a material having low moisture pickup.
  • the carbonates of potassium, sodium and calcium can be used by incorporating one or more of these materials into the filler at suchan early stage of processing that they are converted to the respective oxides which are not sufficiently hygroscopic to pick up excessive amounts of water. This is also true of the oxalates.
  • the carbonate or oxalate should not be added at a stage of processing in which it would be in a hygroscopic form, unless such small amounts are used that the total slag-forming material has an equilibrium moisture content, under the indicated conditions, of less than 2.0 weight percent, or other means are provided to insure that the electrode is applied to the workpiece with a low moisture content, as hereinafter described with respect to another embodiment of the invention.
  • slag-forming material can be used comprising about 53 percent rutile, 21 percent feldspar, l l percent calcium fluoride, 10 percent calcium carbonate, and percent manganese dioxide, or the fusion or decomposition derivative thereof.
  • potassium silicate and some forms of natural clay would be generally unsuitable as components of slag-forming material except under the mollifying conditions just hereinbefore described.
  • the nature of the individual components of the filler can undergo drastic changes in chemical and physical structure during processing of the filler-into the electrode, but the equivalent" amount of calcium fluoride can be calculated from the amount of fluorine which remains which can be attributed to calcium fluoride.
  • the line A-B can be used forother fluxing agents by finding the amount of such agent which is equivalent to calcium fluoride in reacting with water and considering such amount an equivalent" amount.
  • the levels indicated are, of course, approximate as FIG. 2 is intended to relate to a broad range of electrode flux compositions, but by operating in the region below the line A-B, one would generally obtain dense deposits with electrodes that would otherwise be unsuitable for welding stainless steel.
  • fluxing agent any of the other materials referred to above as fluxing agent can be utilized in place of or in combination with the calcium fluoride, e.g., calcium oxide, sodium oxide, and the like, as known to the art. It is generally desirable to use as a fluxing agent material which does not absorb appreciable levels of water, otherwise the additions may be self-defeating in part. If
  • the raw slag and flux materials are formulated to achieve a desired theoretical melted composition after which the mixture is smelted in a continuous furnace.
  • a batch has achieved the desired molten state, it is water quenched, which operation yields a course granulated frit.
  • the frit is then dried, ground and screened to the desired sizing as hereinbefore set forth.
  • the alloying metals are then added and the mixture is formed into electrode wire in a manner previously described with respect to FIG. 1.
  • EXAMPLE 2 An arc welding electrode was formed as hereinbefore described with respect to FIG. 1, utilizing the following components, in percent by weight.
  • each of the above electrodes were tested in welding applications involving an inert gas (argon) treatment. Both electrodes were found to provide very satisfactory fillet welds on stainless steel that were generally smooth and clean with very little splatter and with a well formed, easily removably slag. The weld formed with the one-sixteenth inch diameter electrode was somewhat superior in these characteristics.
  • EXAMPLE 3 Are welding electrodes having one-sixteenth inch and three thirty-second inch diameters were prepared as in Example 2, but utilizing the following components in percent by weight.
  • Rutile Fluorspar (Cam). Manganese oxide. Potassium carbon Zircon Sodium carbonate Potassium silicofluo Sodiu m silieofluoride After weighing, mixing and smelting and foregoing raw batch in a continuous furnace, and after the batch has achieved a molten state, it is water quenched to yield the frit which-is dried, ground and screened through a 200 mesh screen, and then further screened as hereinbefore described. Analysis revealed that the frits had the following theoretical formulas:
  • the frit particles together with the alloying metal particles into the hollow steel tube one may incorporate at that time an additional amount of calcium fluoride or other flux material, as previously discussed, to impart additional protection against moisture.
  • an additional amount of calcium fluoride or other flux material as previously discussed, to impart additional protection against moisture.
  • FIGS. 3 and 4 another embodiment of this invention is illustrated for limiting the moisture content of the arc welding electrode.
  • the propensity of an electrode to form porous weld deposits appears to be related to the amount of moisture present when the electrode is applied to the workpiece.
  • the present embodiment allows one to utilize an electrode which initially has water levels which would ordinarily be in excess of those required for a nonporous weld deposit, e.g., lying above the line A-B of FIG. 2.
  • the present embodiment is based upon the fact that an arc welding electrode is heated in proportion to 1 R so that doubling of the length of the exposed electrode results in quadrupling of heat generated.
  • apparatus is there schematically shown which is adapted to carry out the present embodiment by providing electrode stickout.
  • an arc welding electrode being drawn through a flexible tubular guide 32 and from there through an electrically conductive tubular member 34 which is externally encased in an insulative member 36.
  • the electrode 30 is continuously fed from the conductive tubular member 34 to the workpiece 38 where the welding operation is carried out and effected by circuitry and welding machine components not shown.
  • the terminal portion or stickout of the weld rod is about three-fourth inch from the terminal end 'of the conductive tubular member 34.
  • the forward portion 40 of the outer tubular insulative member 36 is formed with threads which are engaged by a correspondingly threaded portion 42 of a tubular insulative member 44.
  • the 'insulative member 44 can be constructed of any nonconducting material, but is advantageously of a ceramic material which resists expansion upon heating.
  • the insulative member 44 can take any shape and can be connected to the electrode 30 in any manner that is convenient,-
  • any degree of stickout can be provided from the standard three-fourth inch, or less, to several inches or more.
  • an idealized graphical representation is shownfor illustrative purposes and sets forth illustrations of stickout appropriate to various levels of moisture content and fluxing agent concentration, calculated as calcium fluoride (the amount of calcium fluoride is a percent of the electrode weight, whereas the amount of moisture is a percent of the filler weight).
  • the representation is idealized since the actual relationship between stickout and moisture content would depend upon the nature of the specific components utilized to constitute the electrode.
  • analytical methods one can determine the amount of fluxing agent present in terms of effective amounts of calcium fluoride, and can determine the amount of moisture as a percentage of filler in the electrode just prior to use, and with this knowledge, reference can be made to the chart of FIG.
  • an extension member 44 can be chosen to extend the electrode 1.5 inches or more.
  • the extension should beof a length whereby the level of moisture with respect to the amount of the calcium fluoride (or other fluxing agent or fusion or decomposition derivative, calculated as calcium fluoride) is below the level defined by the line A-B, and this may be determined by analysis of the tip of the resistance-heated electrode.
  • the moisture content of the electrode, as applied to the workpiece is limited by special packaging procedures.
  • the electrode is initially obtained in relatively dry form, i.e'., with insufficient moisture therein to cause a porosity problem, and then packaged in such manner that the level of moisture in the electrode prior to use is limited to an amount which would not cause a porosity problem.
  • the electrode is packaged in material having a water-vapor transmission rate sufficiently low to maintain the level of moisture in the electrode prio i touse thereof to an amount insufficient to cause porosity of the weld deposit.
  • the water-vapor transmission of the package material is sufficiently low whereby the level of moisture with respect to the content of the fluxing agent or fusion or decomposition derivative thereof, calculated as calcium fluoride, is below the level defined by the line A-B.
  • the exact water-vapor transmission rate required depends of course upon the projected length of storage. While it would normally appear that one should merely use a material with an extremely low transmission rate, this may be impractical in view of the highly competitive nature of the electrode wire market. Accordingly, the present invention provides a means for determining at least a minimum packaging requirement. The particular-materials utilized and thickness thereof, of course depends upon the composition of the electrode, but the exact amounts and quantities can be calculated utilizing the procedures and information hereinbefore described.
  • the electrode described in Example 3 can be packaged immediately after formulation in a polyethylene wrapper one thirty-second inch thick and stored for several months without yielding porous weld deposits, whereas without such packaging, porous weld deposits are obtained after several months storage of the electrode.
  • a process for forming a stainless steel weld on a workpiece comprising:
  • an arc welding electrode consisting of a hollow tube of steel having as filler (1) one or more alloying metals in amount sufiicient to form a stainless weld of desired composition and (2) slag-forming material including a slag-forming first component and a derivative of a metal having an oxide form when molten different from said first component and soluble in said slag; I said steel tube having a diameter of 0.045 to 0.30 inches, the weight ratio of said filler to said steel tube being 0.2/1 to 1.5/ l and the weight ratio of said slag-forming material to said alloying metals being 0.15/1 to 0.65/1; electrically energizing said electrode; and mechanically feeding said electrode toward said workpiece while maintaining an are between the end of the electrode and the workpiece; the components of said filler being chosen so that said filler, or fusion or decomposition derivative thereof, has an equilibrium moisture content at 70 F.
  • said filler including calcium fluoride, or a fusion or decomposition derivative thereof, in at least an amount cor-- responding to the level of moisture content of said filler as defined by the line A-B of FIG. 2 in the accompanying drawing.
  • said slagforming material is fused into vitreous particlesprior to incorporation into said steel tube.
  • An arc welding electrode consisting of a hollow tube of steel having as filler:
  • slag-forming material including a slag-forming first component and, as a second component, a derivative of metal having an oxide form when molten different from said first component and soluble in said slag; said steel tube having a diameter of 0.045 to 0.30 inches, the weight ratio of said filler to said steel tube being 0.2/1 to 1.5/ l and the weight ratio of said slag-forming to said alloying metals being 0.15/1 to 0.65/1;
  • the components of said filler being chosen so that said filler, or fusion or decomposition derivative thereof has an equilibrium moisture content at 70 F. and 90 percent relative humidity of less than 2.0 weight percent;
  • said filler including calcium fluoride, or a fusion or decomposition derivative thereof, in at leastan amount corresponding to the level of moisture content of said filler as defined by the line A-B of H0. 2 in the accompanying drawing.
  • said slagforming material comprises about 50 percent rutile, about 23 percent Fluorspar, about 1 1 percent manganese oxide, about 7.5 percent potassium carbonate, about 4 percent zircon and about 4 percent alkali metal silicofluoride, or the fusion or decomposition derivative thereof.
  • said slagforming material comprises about 67 percent rutile, about 13 percent calcium fluoride, about 13 percent manganese dioxide and about 7 percent zirconium dioxide, or the fusion or decomposition derivative thereof.
  • said slagforming material comprises about 53 percent rutile 21 percent feldspar, l l percent calcium fluoride, 10 percent calcium carbonate and percent manganese dioxide, or the fusion or decomposition derivative thereof.
  • the invention according to claim 3 including an additional derivative of a metal, different from said first mentioned derivative of metal, having a basic or amphoteric oxide form when molted whereby to impart to said slag-forming material, at the temperature of weld formation, a freezing temperature no higher than the freezing temperature of said weld, and whereby the molten form of said slag-forming material is basic or amphoteric.
  • the invention according to claim 9 including zirconium dioxide as an additional metal derivative.
  • the invention according to claim 9 including calcium carbonate as an additional metal derivative.

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  • Mechanical Engineering (AREA)
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US879045A 1969-11-24 1969-11-24 Arc welding process and electrode for stainless steel Expired - Lifetime US3585352A (en)

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BE (1) BE757977A (no)
CA (1) CA919260A (no)
DE (1) DE2052204A1 (no)
FR (1) FR2071831A5 (no)
GB (1) GB1322076A (no)
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Cited By (28)

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US3767888A (en) * 1971-04-29 1973-10-23 Airco Inc Air wire electrode for stainless steel welding
US3767891A (en) * 1971-05-07 1973-10-23 Lincoln Electric Co Electrode for arc welding in air
US3787658A (en) * 1971-11-03 1974-01-22 Teledyne Inc Tubular arc welding electrode
US3944776A (en) * 1971-02-15 1976-03-16 Junichiro Tsuboi Method of submerged arc welding of high tension steel workpieces
US4149063A (en) * 1977-03-28 1979-04-10 The International Nickel Company, Inc. Flux cored wire for welding Ni-Cr-Fe alloys
JPS62282800A (ja) * 1986-05-30 1987-12-08 Daido Steel Co Ltd ガスシ−ルドア−ク溶接用ワイヤ
JPS63123596A (ja) * 1986-11-11 1988-05-27 Nippon Steel Corp ステンレス鋼溶接用フラツクス入りワイヤ
JPS6448699A (en) * 1987-08-18 1989-02-23 Kobe Steel Ltd Lithium-based stock for flux-cored wire
US5099103A (en) * 1989-12-08 1992-03-24 Kabushiki Kaisha Kobe Seiko Sho Flux-cored wire for gas shielded arc welding
WO1998012011A1 (en) * 1996-09-05 1998-03-26 Randall Davis Electrode extension guide for welding
US6300596B1 (en) * 1997-06-09 2001-10-09 La Soudure Autogene Francaise Flux-cored wire for gas-flow-shielded welding
US20040200820A1 (en) * 2002-03-29 2004-10-14 Illinois Tool Works Inc. Method and apparatus for welding
US20050199317A1 (en) * 2004-03-09 2005-09-15 National Chiao Tung University Welding flux for use in arc-welding of stainless steels, method of welding stainless steel members using the welding flux
US20060081579A1 (en) * 2004-10-18 2006-04-20 Damian J. Kotecki Self-shielded flux cored electrode
US20060096966A1 (en) * 2004-11-08 2006-05-11 Lincoln Global, Inc. Self-shielded flux cored electrode for fracture critical applications
US20060151453A1 (en) * 2001-11-07 2006-07-13 Commonwealth Scientific And Industrial Research Organisation Consumable electrode arc welding
US7812284B2 (en) 2005-07-12 2010-10-12 Lincoln Global, Inc. Barium and lithium ratio for flux cored electrode
US20140131339A1 (en) * 2012-11-13 2014-05-15 Lincoln Global, Inc. Flux moisture control for sub-arc welding process
CN104325232A (zh) * 2014-10-29 2015-02-04 李永锋 耐磨堆焊药芯焊丝
US9370841B2 (en) 2012-10-09 2016-06-21 Randall L. Davis Electrode extension guide for use with welding systems
CN106041364A (zh) * 2016-08-08 2016-10-26 河海大学常州校区 一种耐磨堆焊药芯焊丝
US20160318115A1 (en) * 2015-05-01 2016-11-03 Lincoln Global, Inc. Welding process
USD797171S1 (en) * 2015-02-03 2017-09-12 Coorstek, Inc. Ceramic bonding tool with textured tip
USD797172S1 (en) * 2015-02-03 2017-09-12 Coorstek, Inc. Ceramic bonding tool with textured tip
USD797826S1 (en) * 2015-02-03 2017-09-19 Coorstek, Inc. Ceramic bonding tool with textured tip
USD868123S1 (en) 2016-12-20 2019-11-26 Coorstek, Inc. Wire bonding wedge tool
CN112935620A (zh) * 2021-01-14 2021-06-11 上海欣冈贸易有限公司 一种焊接用金属组合物
CN113399865A (zh) * 2021-07-20 2021-09-17 哈尔滨工业大学（威海） 一种熔渣全覆盖型无飞溅药芯焊丝

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US2951931A (en) * 1956-04-23 1960-09-06 Soudure Electr Autogene Sa Automatic arc welding process, equipment and electrode
US3023130A (en) * 1959-08-06 1962-02-27 Eutectic Welding Alloys Hard surfacing material
US3118053A (en) * 1961-11-09 1964-01-14 Kobe Steel Ltd Composite welding wire
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Cited By (37)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3944776A (en) * 1971-02-15 1976-03-16 Junichiro Tsuboi Method of submerged arc welding of high tension steel workpieces
US3767888A (en) * 1971-04-29 1973-10-23 Airco Inc Air wire electrode for stainless steel welding
US3767891A (en) * 1971-05-07 1973-10-23 Lincoln Electric Co Electrode for arc welding in air
US3787658A (en) * 1971-11-03 1974-01-22 Teledyne Inc Tubular arc welding electrode
US4149063A (en) * 1977-03-28 1979-04-10 The International Nickel Company, Inc. Flux cored wire for welding Ni-Cr-Fe alloys
JPS62282800A (ja) * 1986-05-30 1987-12-08 Daido Steel Co Ltd ガスシ−ルドア−ク溶接用ワイヤ
JPS63123596A (ja) * 1986-11-11 1988-05-27 Nippon Steel Corp ステンレス鋼溶接用フラツクス入りワイヤ
JPS6448699A (en) * 1987-08-18 1989-02-23 Kobe Steel Ltd Lithium-based stock for flux-cored wire
JPH0667558B2 (ja) * 1987-08-18 1994-08-31 株式会社神戸製鋼所 フラックス入りワイヤ用リチウム系原料
US5099103A (en) * 1989-12-08 1992-03-24 Kabushiki Kaisha Kobe Seiko Sho Flux-cored wire for gas shielded arc welding
WO1998012011A1 (en) * 1996-09-05 1998-03-26 Randall Davis Electrode extension guide for welding
US6300596B1 (en) * 1997-06-09 2001-10-09 La Soudure Autogene Francaise Flux-cored wire for gas-flow-shielded welding
US7381923B2 (en) 2001-11-07 2008-06-03 Migfast Pty Ltd Consumable electrode arc welding
US20060151453A1 (en) * 2001-11-07 2006-07-13 Commonwealth Scientific And Industrial Research Organisation Consumable electrode arc welding
US7084372B2 (en) * 2002-03-29 2006-08-01 Illinois Tool Works Inc. Method and apparatus for welding
US20040200820A1 (en) * 2002-03-29 2004-10-14 Illinois Tool Works Inc. Method and apparatus for welding
US7052559B2 (en) * 2004-03-09 2006-05-30 National Chiao Tung University Welding flux for use in arc-welding of stainless steels, method of welding stainless steel members using the welding flux
US20050199317A1 (en) * 2004-03-09 2005-09-15 National Chiao Tung University Welding flux for use in arc-welding of stainless steels, method of welding stainless steel members using the welding flux
US20060081579A1 (en) * 2004-10-18 2006-04-20 Damian J. Kotecki Self-shielded flux cored electrode
US8168922B2 (en) 2004-10-18 2012-05-01 Lincoln Global, Inc. Self-shielded flux cored electrode
US20060096966A1 (en) * 2004-11-08 2006-05-11 Lincoln Global, Inc. Self-shielded flux cored electrode for fracture critical applications
US7812284B2 (en) 2005-07-12 2010-10-12 Lincoln Global, Inc. Barium and lithium ratio for flux cored electrode
US9370841B2 (en) 2012-10-09 2016-06-21 Randall L. Davis Electrode extension guide for use with welding systems
US9321133B2 (en) * 2012-11-13 2016-04-26 Lincoln Global, Inc. Flux moisture control for sub-arc welding process
US20140131339A1 (en) * 2012-11-13 2014-05-15 Lincoln Global, Inc. Flux moisture control for sub-arc welding process
CN104325232A (zh) * 2014-10-29 2015-02-04 李永锋 耐磨堆焊药芯焊丝
USD824970S1 (en) 2015-02-03 2018-08-07 Coorstek, Inc. Ceramic bonding tool with textured tip
USD797171S1 (en) * 2015-02-03 2017-09-12 Coorstek, Inc. Ceramic bonding tool with textured tip
USD797172S1 (en) * 2015-02-03 2017-09-12 Coorstek, Inc. Ceramic bonding tool with textured tip
USD797826S1 (en) * 2015-02-03 2017-09-19 Coorstek, Inc. Ceramic bonding tool with textured tip
USD821468S1 (en) 2015-02-03 2018-06-26 Coorstek, Inc. Ceramic bonding tool with textured tip
USD824969S1 (en) 2015-02-03 2018-08-07 Coorstek, Inc. Ceramic bonding tool with textured tip
US20160318115A1 (en) * 2015-05-01 2016-11-03 Lincoln Global, Inc. Welding process
CN106041364A (zh) * 2016-08-08 2016-10-26 河海大学常州校区 一种耐磨堆焊药芯焊丝
USD868123S1 (en) 2016-12-20 2019-11-26 Coorstek, Inc. Wire bonding wedge tool
CN112935620A (zh) * 2021-01-14 2021-06-11 上海欣冈贸易有限公司 一种焊接用金属组合物
CN113399865A (zh) * 2021-07-20 2021-09-17 哈尔滨工业大学（威海） 一种熔渣全覆盖型无飞溅药芯焊丝

Also Published As

Publication number Publication date
FR2071831A5 (no) 1971-09-17
GB1322076A (en) 1973-07-04
BE757977A (fr) 1971-04-01
NO134452B (no) 1976-07-05
MY7700034A (en) 1977-12-31
NL7015623A (no) 1971-05-26
NO134452C (no) 1976-10-13
CA919260A (en) 1973-01-16
DE2052204A1 (de) 1971-06-09
SE378778B (no) 1975-09-15

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